Power saving on conversion to Bucket elevator:

Power on Poldos blowers: 325 kw

Expected power on Bucket elevator power + other small drives 175 kw

(new bin aeration blower, two air slides, RAL, B.F. fan and small B.E.)
Difference in power 150 kw
Power saving on Pre-heater fan due to reduction in blowers air:

Total air to preheater through material conveying: 14400 m3/hr at 35 OC.

Flow at 345 OC: 32598 m3/hr at 345 OC.
Pre-heater fan total flow 640000 m3/hr at 345 OC.
% reduction in PH fan rpm 5.00 %
Rpm reduction in PH fan 49 rpm
Power reduction 218 kw

(Fan rpm can be reduced or kiln feed can be incresed depends on suitability of other equipment)

Fuel saving:
Heat saving per Kg clinker (rule of thumb) 3 kcal
Energy saving per hour 465000 kcal
Fuel saving in terms of coal 79 kgs coal/hr

Total power saving per hour 368 kw

Total coal saving per hour 79 kgs

Total saving per hr, in rupees 2407 Rs.

Total saving per 330 days of operation, in rupees 190.6 Lacs. Per year
Savings on Cooler replacement:
Heat losses from the present cooler:
Heat in cooler exhaust gases 110 kcal/kg clk
Heat carried out by clinker leaving cooler 32 kcal/kg clk
Total 142 kcal/kg clk

Expected heat losses from latest cooelrs 105 kcal/kg clk

Savings 37 kcal/kg clk

Savings in terms coal for 330 operating days 7764

ID fan power saving:

Present fan power consumption 1.03 kwh/t . clk
Expected power after modification 0.75 kwh/t . clk

Power saving 346500 kwh/t . clk

Total saving for 330 days operation 576.36 Lacs Rupees